T-SB-0009-15_Rev

T-SB-0009-15
Rev1
February 12, 2015
TRD Pro Bumper/Fender Interference
Service
Category
Suspension
Section
Tire/Wheel
USA
Market
Applicability
YEAR(S)
MODEL(S)
2015 – 2017
4Runner
ADDITIONAL INFORMATION
REVISION NOTICE
September 19, 2017 Rev1:
• Applicability has been updated to include 2016 – 2017 model year 4Runner vehicles.
Any previous printed versions of this bulletin should be discarded.
Introduction
Some 2015 – 2017 model year TRD Pro edition 4Runner vehicles may exhibit an abnormal noise
when in Reverse with the wheels at or near full lock due to interference between the tire and bumper
and/or fender liner. Follow the Repair Procedure in this bulletin to address this condition.
Parts Information
PART NUMBER
PART NAME
QTY
PTR25-89150
4Runner TRD Pro Trim Kit*
1
*CONTENTS OF 4RUNNER TRD PRO TRIM KIT
QTY
LH & RH Bumper Cover Marking Templates
1 Each
3M™ Foam Sanding Block
1
Clamp
1
Modified Channellock Cutting Plier
1
LH & RH Metal Fender Liner Templates
1 Each
Double-sided Foam Tape
1
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TRD Pro Bumper/Fender Interference
Warranty Information
OP CODE
DESCRIPTION
TIME
OFP
T1
T2
BD1505
Fender/Bumper Trim Modification
1.0
52119-35914
94
57
APPLICABLE WARRANTY
• This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months
or 36,000 miles, whichever occurs first, from the vehicle’s in-service date.
• Warranty application is limited to occurrence of the specified condition described in
this bulletin.
Required Tools & Equipment
SPECIAL SERVICE TOOLS (SST)
PART NUMBER
QTY
Plastic Pry Tool Kit*
00002-06020-01
1
* Essential SST.
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
REQUIRED TOOLS & MATERIAL
QUANTITY
Electric Drill
1
Step Drill Bit
1
Wax Pencil
1
Center Punch
1
Cutters
1
Lint-free Cloth
1
Masking Tape
As Needed
© 2017 Toyota Motor Sales, USA
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TRD Pro Bumper/Fender Interference
Repair Procedure
Fender Liner Modification
1. Confirm the abnormal noise condition described in the Introduction.
2. Remove the front wheels.
3. Beginning with the driver side, remove the two fasteners on the lower side of the fender liner.
Figure 1.
4. Unclip the fender liner and carefully pull it toward
the rear of the vehicle.
Figure 2.
© 2017 Toyota Motor Sales, USA
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TRD Pro Bumper/Fender Interference
Repair Procedure (Continued)
Fender Liner Modification (Continued)
5. Install the driver side (LH) metal fender liner template (from the TRD Pro Trim Kit) on the front
side of the fender liner.
NOTE
Be sure to place the alignment pins into the two existing holes.
Figure 3.
Figure 4.
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TRD Pro Bumper/Fender Interference
Repair Procedure (Continued)
Fender Liner Modification (Continued)
6. Use a wax pencil to outline two NEW holes and the area to be removed.
Figure 5.
7. Use a center punch to mark the center of the two holes and remove the template.
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TRD Pro Bumper/Fender Interference
Repair Procedure (Continued)
Fender Liner Modification (Continued)
8. Using cutters, remove the marked plastic area as shown.
Figure 6.
Figure 7.
1
1
Before Cut
2
2
© 2017 Toyota Motor Sales, USA
After Cut
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TRD Pro Bumper/Fender Interference
Repair Procedure (Continued)
Fender Liner Modification (Continued)
9. Using the step drill bit, drill two holes in the fender liner at the identifying marks.
NOTE
Set the drill stop to 5/16 – 3/8 in. (8 – 9 mm) and drill both sides to remove the flash from
the fender liner.
Figure 8.
10. Repeat the same procedure for the passenger side.
NOTE
Be sure to use the passenger side (RH) template.
© 2017 Toyota Motor Sales, USA
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TRD Pro Bumper/Fender Interference
Repair Procedure (Continued)
Front Bumper Cover Modification
PRECAUTIONS & PROPER USE OF CUTTING PLIERS
Before proceeding it is important to understand the proper use of the cutting pliers. Read this
section thoroughly to ensure proper use BEFORE modifying the front bumper cover.
• One side of the pliers is marked red. THE
RED SIDE OF THE PLIERS IS TO BE USED
AGAINST THE PAINTED SURFACE ONLY
(paint against paint).
Figure 9.
1
1
Red Side
• When holding the cutting pliers in place, it is important to keep the pliers oriented at a
90 degree angle as shown.
Figure 10.
5
2
1
3
4
1
Bumper Cover
4
Red Jaw
2
Paint
5
Edge Must Be 90◦ to Surface
3
Tape
© 2017 Toyota Motor Sales, USA
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TRD Pro Bumper/Fender Interference
Repair Procedure (Continued)
Front Bumper Cover Modification (Continued)
PRECAUTIONS & PROPER USE OF CUTTING PLIERS (Continued)
• DO NOT TAKE FULL CUTS across the face
of the bumper cover. ONLY MAKE HALF
CUTS BEFORE MOVING TO MAKE THE
NEXT CUT.
Figure 11.
NOTICE
1
Failure to make only partial cuts
may result in uneven cuts or a wavy
appearance and the bumper may
need to be replaced.
1
Start at Top and Move Down
Figure 12. Half Cuts Along Same Line
1
2
1
Cut 1
2
Cut 2
© 2017 Toyota Motor Sales, USA
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TRD Pro Bumper/Fender Interference
Repair Procedure (Continued)
Front Bumper Cover Modification (Continued)
PRECAUTIONS & PROPER USE OF CUTTING PLIERS (Continued)
Figure 13. Example of Half Cuts
1
2
3
4
1
Cut 1
3
Cut 3
2
Cut 2
4
Cut 4
• Because the depth of the cutting pliers is less than the maximum depth of area to be
removed, it is necessary to first make a preliminary cut removing approximately half of the
area (between the arrows).
Figure 14.
2
1
1
Depth of Cutting Pliers
2
Remove Area Between Arrows
© 2017 Toyota Motor Sales, USA
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TRD Pro Bumper/Fender Interference
Repair Procedure (Continued)
Front Bumper Cover Modification (Continued)
PRECAUTIONS & PROPER USE OF CUTTING PLIERS (Continued)
Figure 15. Good Example
Figure 16. Bad Example
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Repair Procedure (Continued)
Front Bumper Cover Modification (Continued)
1. Carefully pull the fender liner back and secure it to the lower control arm.
Figure 17.
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TRD Pro Bumper/Fender Interference
Repair Procedure (Continued)
Front Bumper Cover Modification (Continued)
2. Using warm water and a lint-free cloth, clean the work area ensuring ALL debris is removed.
Figure 18.
3. Locate the LH bumper template and secure it to
the bumper cover with a clamp.
Figure 19.
© 2017 Toyota Motor Sales, USA
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TRD Pro Bumper/Fender Interference
Repair Procedure (Continued)
Front Bumper Cover Modification (Continued)
4. Cut an 8-inch (203 mm) strip of double-sided
foam tape and apply it to the edge of the marking
template. Ensure the tape is straight and flush
against the template.
Figure 20.
.
Figure 21.
.
NOTE
• Do NOT remove the backing from the tape.
• When repeating this for the opposite side,
always use a NEW piece of tape.
5. Remove the marking template and clamp.
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TRD Pro Bumper/Fender Interference
Repair Procedure (Continued)
Front Bumper Cover Modification (Continued)
6. Make the preliminary cut removing approximately
half of the area (between the arrows).
Figure 22.
.
7. Starting at the outer edge, trim along the tape
working toward the inside with overlapping cuts.
Figure 23.
.
NOTICE
Prior to each cut, ensure the cutting pliers are
held at a 90 degree angle and rest against the
tape. Failure to do so may result in uneven cuts
and the bumper cover will require replacement.
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TRD Pro Bumper/Fender Interference
Repair Procedure (Continued)
Front Bumper Cover Modification (Continued)
8. Once the cutting is complete, remove the tape.
9. Apply masking tape to the painted edge of the bumper cover just above and below the top
of the cut.
Figure 24.
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TRD Pro Bumper/Fender Interference
Repair Procedure (Continued)
Front Bumper Cover Modification (Continued)
10. Use the foam sanding block to lightly sand the cut edges to remove any sharp edges or burrs.
When sanding, use light pressure and keep the block square with the edge. Only a few strokes
should be required to ensure the edges are smooth.
Figure 25.
11. Remove the tape and clean the bumper surface as performed in step 2.
12. Return the fender liner back to its original position and reinstall the two fender liner fasteners.
NOTE
The fasteners MUST be inserted into the two NEW holes drilled in step 9 of the Fender Liner
Modification section with the silver fastener in the front location and the black fastener
in the rear location.
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TRD Pro Bumper/Fender Interference
Repair Procedure (Continued)
Front Bumper Cover Modification (Continued)
13. Using your hands, verify the fender liner and
bumper are flush.
Figure 26.
.
14. Repeat both procedures (Fender Liner Modification and Front Bumper Cover Modification) on
the passenger side of the vehicle.
15. Install the front wheels.
Refer to the Technical Information System (TIS):
Accessory – Accessories Installation – “2010 – 2017 4Runner, 2007 – 2017 FJ Cruiser TRD
Alloy Wheel PTR20-35110-BK Matte Black, PTR20-35110-GR Graphite Gray Rev. B”
© 2017 Toyota Motor Sales, USA